Energy-absorbing device and sill assembly having energy-absorbing device

Abstract

An energy absorbing device and a sill assembly for use in a vehicle are provided. In one aspect, an energy absorbing device includes a plate formed from a composite material. The panel includes a width extending along a width of the vehicle and a length extending along a length of the vehicle. The plate has a sinusoidal form formed along the length of the plate. The sill assembly includes an inner sill and an outer sill coupled together to enclose an interior space. A carrier is disposed within the interior space, wherein the carrier is configured to hold an energy absorbing device disposed within the interior space.

Description

[0001] INTRODUCTION

[0002] The information provided in this section is for the purpose of generally presenting the context of the disclosure. The work of the presently named inventors, to the extent the work is described in this section, as well as aspects of the description that can not be prior art to the disclosure, are neither expressly nor impliedly admitted to be prior art against the disclosure. TECHNICAL FIELD

[0003] The present disclosure relates generally to energy absorbing devices and rocker panels for vehicles, and more particularly, to energy absorbing devices and rocker panels configured to tailor to specific load requirements using a composite material having a sinusoidal form. BACKGROUND

[0004] Vehicles, such as automobiles, trucks, buses, and the like, are designed to protect occupants and vehicle components from damage or injury in the event of a collision or impact. One way in which this protection is achieved is by providing energy absorbing devices and structures that are capable of deforming or crushing under a load and dissipating the kinetic energy of an impact. For example, vehicles can have bumpers, crumple zones, side beams, and other components that act as energy absorbers.

[0005] In particular, vehicles can include a rocker panel assembly that is attached along a floor of the vehicle and extends from a front of the vehicle to a rear of the vehicle. The rocker panel assembly includes an inner rocker and an outer rocker and is formed from a metallic material. In this configuration, the rocker panel assembly is configured to absorb energy from a front or rear impact with higher efficiency relative to a side impact. Moreover, metallic structures can have limitations in terms of weight, cost, performance, and design flexibility. For example, metal-based energy absorbers can be heavy, expensive, susceptible to corrosion, and difficult to shape or modify. Moreover, metal-based energy absorbers can have a limited range of deformation and energy absorption capabilities.

[0006] Accordingly, it is still desirable to provide an energy absorbing device and rocker panel assembly for a vehicle that can be tailored and configured to provide different load absorption characteristics at different regions. SUMMARY

[0007] In one configuration, an energy absorbing device for use in a vehicle includes a panel formed from a composite material. The panel has a width extending along a width of the vehicle and a length extending along a length of the vehicle, wherein the panel has a sinusoidal form formed along the length of the panel.

[0008] The energy absorbing device can include one or more of the following optional features. For example, the thickness of the material plate varies along the length of the plate. In another aspect, the plate includes a plurality of arcuate sections along a sinusoidal form, wherein the number of arcuate sections in the load portion is greater than the number of arcuate sections in the non-load portion, thereby enhancing energy absorbing efficiency and reducing the weight of the plate.

[0009] In one configuration, the plate is a first material plate and a second material plate, wherein the first material plate is joined to the second material plate to form a plurality of tubes interconnected to one another by neck portions.

[0010] In one configuration, the composite material is one selected from a group comprising: a carbon fiber reinforced polymer, a glass fiber reinforced polymer, an aramid fiber reinforced polymer, and a natural fiber reinforced polymer.

[0011] In one configuration, a rocker assembly for use in a vehicle is provided. The rocker assembly includes an inner rocker and an outer rocker coupled together so as to enclose an interior space. The inner rocker and the outer rocker extend along a length of the vehicle. The rocker assembly further includes a carrier and an energy absorbing device. The carrier is disposed within the interior space and is configured to hold the energy absorbing device. The energy absorbing device is a plate formed of a composite material. The plate has a length extending along a length of the inner rocker and a width extending between the inner rocker and the outer rocker, wherein the plate has a sinusoidal form extending along the length of the plate.

[0012] The rocker assembly can include one or more of the following optional features. For example, the inner rocker and the outer rocker can be made of a metal, such as steel, aluminum, or any alloy thereof. In another aspect, the carrier includes a first flange configured to be attached between the inner rocker and the outer rocker and a fastening member for attachment to one of the inner rocker or the outer rocker, thereby securing the carrier and the energy absorbing device within the interior space.

[0013] In one configuration of the rocker assembly, the thickness of the material plate varies.

[0014] In one configuration, the plate includes a plurality of arcuate sections along a sinusoidal form, and the number of arcuate sections in the load portion is greater than the number of arcuate sections in the non-load portion.

[0015] In one configuration, the plate includes a plurality of tubes interconnected to one another by neck portions.

[0016] In one configuration of the rocker assembly, the composite material is one selected from a group comprising: a carbon fiber reinforced polymer, a glass fiber reinforced polymer, an aramid fiber reinforced polymer, and a natural fiber reinforced polymer.

[0017] In one configuration of the rocker assembly, the carrier includes a planar surface extending along a length of the panel and between the panel and at least one of the inner rocker and the outer rocker.

[0018] In yet another configuration, a vehicle is provided. The vehicle includes a chassis extending along a length of the vehicle between a front of the vehicle and a rear of the vehicle, and a plurality of cross members extending along a width of the vehicle. The vehicle includes a rocker assembly disposed on the chassis and extending along the length of the vehicle. The rocker assembly includes an inner rocker, an outer rocker, a carrier, and an energy absorbing device. The inner rocker and the outer rocker are coupled together so as to enclose an interior space, wherein the carrier is disposed within the interior space and is configured to retain the energy absorbing device disposed within the interior space. The energy absorbing device is a panel formed of a composite material. The panel has a length extending along a length of the inner rocker and a width extending between the inner rocker and the outer rocker, wherein the panel has a sinusoidal form extending along the length of the panel.

[0019] The vehicle can include one or more of the following optional features. For example, the inner rocker and the outer rocker can be made of a metal, such as steel, aluminum, or any alloy thereof. In another aspect, the thickness of the panel of material varies. In yet another aspect, the carrier includes a planar surface extending along a length of the panel and between the panel and at least one of the inner rocker and the outer rocker.

[0020] In one configuration, the panel includes a plurality of arcuate sections along the sinusoidal form, and a number of the arcuate sections in the load portion is greater than a number of the arcuate sections in the non-load portion.

[0021] In one configuration, the panel is a first panel of material and a second panel of material, wherein the first panel of material is joined to the second panel of material to form a plurality of tubes interconnected to each other by a neck portion.

[0022] The present disclosure provides the following technical solutions:

[0023] 1. An energy absorbing device for use in a vehicle, the energy absorbing device comprising:

[0024] a panel formed of a composite material, the panel having a width extending along a width of the vehicle and a length extending along a length of the vehicle, wherein the panel has a sinusoidal form formed along the length of the panel.

[0025] 2. The energy absorbing device of technical solution 1, wherein a thickness of the panel of material varies.

[0026] 3. The energy absorbing device of technical solution 1, wherein the sinusoidal form is irregular.

[0027] 4. The energy absorbing device of claim 3, wherein the panel comprises a plurality of arcuate sections along the sinusoidal form, and the number of arcuate sections in the load portion is greater than the number of arcuate sections in the non-load portion.

[0028] 5. The energy absorbing device of claim 1, wherein the panel is a first material panel and a second material panel, the first material panel joined to the second material panel to form a plurality of tubes interconnected to each other by a neck portion.

[0029] 6. The energy absorbing device of claim 1, wherein the composite material is one selected from a group comprising: carbon fiber reinforced polymer, glass fiber reinforced polymer, aramid fiber reinforced polymer, and natural fiber reinforced polymer.

[0030] 7. A rocker assembly for use in a vehicle, the rocker assembly comprising:

[0031] an inner rocker and an outer rocker coupled together so as to enclose an interior space, the inner rocker and the outer rocker extending along a length of the vehicle;

[0032] a carrier disposed within the interior space; and

[0033] an energy absorbing device disposed within the interior space and held by the carrier, wherein the energy absorbing device is a panel formed of a composite material, the panel having a length extending along the length of the inner rocker and a width extending between the inner rocker and the outer rocker, wherein the panel has a sinusoidal form extending along the length of the panel.

[0034] 8. The rocker assembly of claim 7, wherein the inner rocker and the outer rocker are made of metal.

[0035] 9. The rocker assembly of claim 7, wherein the carrier comprises a first flange configured to be attached between the inner rocker and the outer rocker.

[0036] 10. The rocker assembly of claim 7, wherein the carrier comprises a fastening member for attachment to one of the inner rocker or the outer rocker.

[0037] 11. The rocker assembly of claim 7, wherein a thickness of the panel varies.

[0038] 12. The rocker assembly of claim 7, wherein the panel comprises a plurality of arcuate sections along the sinusoidal form, and the number of arcuate sections in the load portion is greater than the number of arcuate sections in the non-load portion.

[0039] 13. The rocker assembly of claim 7, wherein the panel comprises a plurality of tubes interconnected to one another by neck portions.

[0040] 14. The rocker assembly of claim 7, wherein the composite material is one selected from a group comprising: carbon fiber reinforced polymer, glass fiber reinforced polymer, aramid fiber reinforced polymer, and natural fiber reinforced polymer.

[0041] 15. The rocker assembly of claim 7, wherein the carrier comprises a planar surface extending along a length of the panel and between the panel and at least one of the inner rocker and the outer rocker.

[0042] 16. A vehicle comprising a chassis extending along a length of the vehicle between a front and a rear of the vehicle, and a plurality of cross members extending along a width of the vehicle, the vehicle comprising:

[0043] a rocker assembly disposed on the chassis and extending along the length of the vehicle, the rocker assembly comprising an inner rocker, an outer rocker, and a carrier, the inner rocker and the outer rocker coupled together to enclose an interior space, wherein the carrier is disposed within the interior space; and

[0044] an energy absorbing device disposed within the interior space and retained by the carrier, wherein the energy absorbing device is a panel formed of a composite material, the panel having a length extending along a length of the inner rocker and a width extending between the inner rocker and the outer rocker, wherein the panel has a sinusoidal form extending along the length of the panel.

[0045] 17. The vehicle of claim 16, wherein the carrier comprises a planar surface extending along the length of the panel and between the panel and at least one of the inner rocker and the outer rocker.

[0046] 18. The vehicle of claim 16, wherein a thickness of the panel of material varies.

[0047] 19. The vehicle of claim 16, wherein the panel comprises a plurality of arcuate sections along the sinusoidal form, and a number of arcuate sections in a load portion is greater than a number of arcuate sections in a non-load portion.

[0048] 20. The vehicle of claim 16, wherein the panel is a first panel of material and a second panel of material, the first panel of material joined to the second panel of material to form a plurality of tubes interconnected to one another by neck portions. BRIEF DESCRIPTION OF DRAWINGS

[0049] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0050] Figure 1 is a perspective view of a vehicle including an energy absorbing device according to the present disclosure;

[0051] Figure 2 is Figure 1 is a cross-sectional view of the energy absorbing device of the vehicle shown taken along line 2-2.

[0052] Figure 3 is Figure 1 is a cross-sectional view of the energy absorbing device of the vehicle shown taken along line 3-3.

[0053] Figure 4 is an assembled view of a rocker assembly according to the present disclosure;

[0054] Figure 5 is Figure 4 is a perspective exploded view of the rocker assembly shown.

[0055] Figure 6 is a perspective exploded view of Figure 4 is a perspective exploded view of the carrier and energy absorbing device shown.

[0056] Figure 7 is a perspective exploded view of a rocker assembly according to another aspect of the present disclosure.

[0057] Figure 8 is Figure 7 is a perspective exploded view of the energy absorbing device shown.

[0058] Figure 9 is a plan view of the energy absorbing device from the side.

[0059] Figure 10 is an exploded view of an energy absorbing device according to another aspect of the present disclosure.

[0060] Figure 11 is an exploded view of an energy absorbing device according to another aspect of the present disclosure.

[0061] In all of the drawings, corresponding reference characters indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0062] Example constructions will now be described more fully with reference to the accompanying drawings. Example constructions are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Specific details are set forth in order to provide a thorough understanding of the example constructions. It will be apparent to one skilled in the art, however, that the example constructions can be embodied in many different forms without departing from the scope of the present disclosure. Reference will be made to specific

[0063] The terminology used herein is for the purpose of describing particular example configurations only and is not intended to be limiting. As used herein, the singular articles "a," "an," and "the" can be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order

[0064] When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it can be directly on, engaged, connected, attached, or coupled to the other element or layer, or one or more intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0065] The terms "first," "second," "third," etc. can be used herein to describe various elements, components, regions, layers and / or sections. Such elements, components, regions, layers and / or sections should not be limited by such terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terminology do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

[0066] In this application, including the following claims, the term "module" can refer to, be part of, or include an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; a memory (shared, dedicated, or group) that stores code for execution by a processor (shared, dedicated, or group); other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

[0067] The term "code," as used in this application, can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. The term "shared processor" encompasses a single processor that executes some or all code from multiple modules. The term "group processor" encompasses a processor that, in combination with additional processors, executes some or all code from one or more modules. The term "shared memory" encompasses a single memory that stores some or all code from multiple modules. The term "group memory" encompasses a memory that, in combination with additional memory, stores some or all code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium." The term "computer-readable medium" does not encompass transitory propagating signals and thus can be considered tangible and non-transitory. Non-limiting examples of non-transitory computer-readable media include nonvolatile memory, magnetic storage, and optical storage.

[0068] The apparatus and methods described in this application can be implemented partially or wholly by one or more computer programs executed by one or more processors. The computer programs include processor-executable instructions stored on at least one non-transitory, tangible computer-readable medium. The computer programs can also include and / or rely on stored data.

[0069] A software application (i.e., a software resource) can refer to computer software that causes a computing device to perform a task. In some examples, a software application can be referred to as an "application program," an "app," or a "program." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0070] A non-transitory memory can be a physical device that is used to temporarily or permanently store programs (e.g., sequences of instructions) or data (e.g., program state information) for use by a computing device. A non-transitory memory can be a volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used for firmware such as a boot program). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM), and disks or tapes.

[0071] These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and / or object-oriented programming language, and / or in assembly / machine language. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer readable medium, devices and / or means used to provide machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0072] Various implementations of the systems and techniques described herein can be realized in digital electronic and / or optical circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and / or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

[0073] The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit). Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical, or optical disks, or a removable disk. However, a computer need not have such devices. Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

[0074] To provide for interaction with a user, one or more aspects of the disclosure can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube), LCD (liquid crystal display), or touch screen, for displaying information to the user and optionally a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to and receiving documents from a device used by the user; for example, by sending web pages to a web browser on a user’s client device in response to requests received from the web browser.

[0075] An energy absorbing device includes a panel formed of a composite material, where the panel has a width extending along a width of a vehicle and a length extending along a length of the vehicle, where the panel has a sinusoidal form formed along the length of the panel so as to absorb energy from a side impact. The panel can be adjustable so as to provide different energy absorbing characteristics at different locations along the length of the panel. Thus, the energy absorbing device can be configured to provide different levels of stiffness and energy absorbing capacity to accommodate the vehicle structure.

[0076] Referring to Figure 1 , a vehicle 10 is provided. The vehicle 10 includes an energy absorbing device 12 extending along a length of the vehicle 10. For exemplary purposes, the energy absorbing device 12 is shown mounted to a chassis 14 of the vehicle 10. In particular, the energy absorbing device 12 is shown mounted to the chassis 14 and extending between a front wheel well 16 and a rear wheel well 18. For illustrative purposes, the energy absorbing device 12 is shown disposed on a driver side of the vehicle 10. However, it should be appreciated that the energy absorbing device 12 can be disposed in other locations of the vehicle 10 to provide impact absorbing functionality. For example, the vehicle 12 can include another energy absorbing device 12 extending between the front wheel well 16 and the rear wheel well 18, the front wheel well 16 and the rear wheel well 18 also being disposed on a front passenger side of the vehicle 10, or extending along a front or rear bumper.

[0077] Referring now to Figure 2 and 3 , cross-sectional views of the energy absorbing device 12 taken along lines 2-2 and 3-3 of Figure 1 are provided. The chassis 14 is made of a durable, rigid material, such as steel, and can include a plurality of cross members 20 and a pair of rocker assemblies 22. The rocker assemblies 22 are spaced apart from each other and are generally parallel and extend along a length of the vehicle 10. Each end of the cross members 20 is joined to the pair of rocker assemblies 22 so as to extend across a width of the vehicle 10.

[0078] The chassis 14 can be configured to support various vehicle components 24, such as a battery assembly 24a. The battery assembly 24a can include a housing 26 for housing a battery (not shown) and various electrical components, such as wires, fuses, relays, etc. (not shown). In one aspect, the cross members 20 can be disposed above the battery assembly 24a, and the battery assembly 24a can be attached to the cross members 20 using known attachment techniques, such as bolts, screws, brackets, etc.

[0079] Referring again to Figure 2 and 3 , and now referring to Figure 5A description of the rocker assembly 22 is provided. The rocker assembly 22 includes an inner rocker 28 and an outer rocker 30 that are coupled together and configured to retain the energy absorbing device 12. When the rocker assembly 22 is assembled, the outer rocker 30 is disposed outwardly of the inner rocker 28. The outer rocker 30 includes an outer middle portion 32, an outer upper flange 34, and an outer lower flange 36. The outer upper flange 34 and the outer lower flange 36 are disposed on opposite ends of the outer middle portion 32. The outer middle portion 32 has a generally U-shaped cross-section.

[0080] The inner rocker 28 includes an inner middle portion 38, an inner upper flange 40, and an inner lower flange 42. The inner upper flange 40 and the inner lower flange 42 are disposed on opposite ends of the inner middle portion 38. The inner middle portion 38 has a generally U-shaped cross-section when viewed along its width. The outer upper flange 34 and the inner upper flange 40 are attached to one another, and the outer lower flange 36 and the inner lower flange 42 are attached to one another, with the inner middle portion 38 and the outer middle portion 32 spaced apart from one another to form an interior space 44 for housing the energy absorbing device 12. It should be appreciated that the outer upper flange 34, the inner upper flange 40, the outer lower flange 36, and the inner lower flange 42 can be attached to one another using known attachment techniques, including welding, mechanical fasteners, adhesives, and the like.

[0081] Referring now to Figure 6 and Figure 8 The rocker assembly 22 can further include a carrier 46. The carrier 46 is also formed of a rigid and durable material, such as steel, and is configured to retain the energy absorbing device 12 within the interior space 44. The carrier 46 is an elongated member having a generally U-shaped cross-section configured to support the energy absorbing device 12. In particular, the carrier 46 includes a base 48, a top plate portion 50 spaced apart from the base 48, and a back wall 52 interconnecting the base 48 and the top plate portion 50. The base 48 and the top plate portion 50 are generally planar surfaces extending the length of the carrier 46. The base 48 and the top plate portion 50 are spaced apart from one another so as to properly receive the energy absorbing device 12 with a bottom portion of the energy absorbing device 12 resting on the base 48 of the carrier 46. In this manner, the carrier 46 retains the energy absorbing device 12 within the interior space 44 of the rocker assembly 22.

[0082] The carrier 46 includes attachment structure for attachment to the rocker assembly 22. For example, the carrier 46 can include a plurality of through holes 54 for receiving bolts 56 that pass through one of the inner rocker 28 or the outer rocker 30 so as to secure the carrier 46 thereto. Figure 2Aspects are shown in which the bolt 56 passes through the outer rocker 30 and the nut 58 is disposed within the interior space 44. The bolt 56 is threaded into the nut 58 so as to secure the carrier 46 to the outer rocker 30. In one aspect, the panel 12 is free of any holes and is supported within the rocker assembly 22 solely by the carrier 46. As such, the integrity of the panel 12 is not compromised as the panel 12 is smooth and continuous. The carrier 46 is not configured to provide an energy absorbing function, but rather is configured to hold the energy absorbing device 12 within the interior space 44.

[0083] In another aspect of the attachment structure, the carrier 46 can include one or more flanges 60 that can be secured to the carrier 46 using any known or later developed attachment technique, including welding, fasteners, and adhesives, among others. As shown in Figure 2 and 3 The flanges 60 are sandwiched between the corresponding outer upper flange 34, inner upper flange 40, outer lower flange 36, and inner lower flange 42. As such, the carrier 46 holds the energy absorbing device 12 within the interior space 44 of the rocker assembly 22.

[0084] Referring now to Figure 5 , 6 and 9, a depiction of the energy absorbing device 12 is provided. The energy absorbing device 12 is a panel 62 formed of a composite material. The energy absorbing device 12 has a length "L" that extends along the length of the vehicle 10 and a width "W" that extends along the width of the vehicle 10. Figure 5 and 6 One aspect is depicted in which the panel 62 has a generally uniform thickness "T". The panel 62 has a generally sinusoidal form 64 formed along the length L of the panel 62. That is, the panel 62 forms a plurality of waves that abut one another along the length "L" of the panel 62. The sinusoidal form 64 can be regular in that each wave can have the same wavelength "WL" and the same amplitude "A", as indicated in Figure 9 . Figure 5 and Figure 6 One aspect is depicted in which the sinusoidal form 64 is irregular in that the wavelength "WL" and the amplitude "A" of each wave varies along the length of the panel 62.

[0085] The composite material of the plate 62 can be a material selected from the group including carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), aramid fiber reinforced polymer (AFRP), and natural fiber reinforced polymer (NFRP). The material can be fixed or otherwise bound by a thermoset polymer, a thermoplastic polymer, or any combination thereof. The composite material can have a high strength-to-weight ratio, a high stiffness-to-weight ratio, high fatigue resistance, high corrosion resistance, and high thermal stability. The composite material can also have a low density, low cost, and high recyclability. The composite material can be formed by impregnating fibers with a resin matrix, such as an epoxy resin, a polyester, a vinyl ester, or any other suitable resin. The fibers can be arranged in various orientations, such as unidirectional, bidirectional, multidirectional, woven, non-woven, or any combination thereof. The plate 62 can be formed by molding, curing, cutting, pultrusion, or any other suitable process.

[0086] The thermoset polymer is independently selected from the group including benzoxazine, bismaleimide (BMI), cyanate ester, epoxy, phenol formaldehyde (PF), polyacrylate (acrylic), polyimide (PI), unsaturated polyester, polyurethane (PUR), vinyl ester, siloxane, copolymers thereof, and combinations thereof.

[0087] The thermoplastic polymer is independently selected from the group including polyethyleneimine (PEI), polyamideimide (PAI), polyamide (PA) (e.g., nylon 6, nylon 66, nylon 12), polyether ether ketone (PEEK), polyether ketone (PEK), polyphenylene sulfide (PPS), thermoplastic polyurethane (TPU), polypropylene (PP), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), high-density polyethylene (HDPE), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polycarbonate (PC), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), copolymers thereof, and combinations thereof.

[0088] Referring again to Figure 9 , a plan view is provided taken along a side of the energy absorbing device 12. Figure 9An aspect is shown in which the wavelength "WL" and amplitude "A" of each wave is substantially the same, and thus each wave forming the sinusoidal form 64 has the same number of arcuate sections as one another. However, the thickness "T" of the panel 62 varies along the length L of the panel 62. For example, the thickness "T" of the load portion 66 of the panel 62 can be greater than the thickness of the non-load portion 68 of the panel 62. For example, the thickness "T" can be greater where the cross-car beam 20 or battery assembly 24a is adjacent the area of the energy absorption device 12 as compared to the area of the energy absorption device 12 where neither the cross-car beam 20 nor the vehicle component 24 is present. The load portion 66 can be the portion of the panel 62 positioned to receive a higher load or impact force than the non-load portion 68. For example, the load portion 66 can be adjacent the cross-car beam 20 as shown in Figure 2 or the vehicle 10 component such as the battery assembly 24a as shown in Figure 3 The non-load portion 68 can be the portion of the panel 62 where the rocker assembly 22 is not directly connected to the vehicle structure, and thus, the impact and load absorption characteristics are tuned for a lower load or impact force as compared to the load portion 66. For example, the non-load portion 68 can be the area along the rocker assembly 22 that does not have the cross-car beam 20 or vehicle component 24. Thus, it should be appreciated that the term "non-load" does not mean that the corresponding area of the panel 62 is not susceptible to impact. The entire panel 62 is configured to provide energy absorption functionality. Figure 9 The load portion 66 of the panel 62 is shown corresponding to a thicker area of the panel 62, and thus, the non-load portion 68 corresponds to a thinner area of the panel 62. It should also be appreciated that the thickness "T" of the load portion 66 can vary in order to tune to the desired load absorption characteristics.

[0089] By varying the thickness "T" of the panel 62, the stiffness and energy absorption capacity of the panel 62 can be tuned according to the expected load or impact force. For example, a thicker panel 62 can have a higher stiffness and a higher energy absorption capacity than a thinner panel 62. Thus, the energy absorption device 12 can provide a variable stiffness and energy absorption capacity along the length L of the panel 62, thereby enhancing the performance and efficiency of the energy absorption device 12. Using Figure 2 and 3 As an example, the thickness "T" of the panel 62 can be greater where both the cross-car beam 20 and the vehicle component 24 are in contact with the rocker assembly 22 as shown in Figure 3 as compared to the thickness "T" of the panel where only the cross-car beam 20 is in contact with the rocker assembly 22. Further, the thickness "T" of the panel 62 where the rocker assembly 22 is free of the cross-car beam 20 can be thinner than the thickness "T" of the panel 62 where the rocker assembly 22 is in contact with the cross-car beam 20.

[0090] Referring again to Figures 5-7The sinusoidal form 64 can include a plurality of arcuate segments 70 that abut one another and along the sinusoidal form 64. The arcuate segments 70 can have a curved or rounded shape in order to reduce or eliminate the linear length of the sinusoidal form 64 that extends between the peaks and valleys of the sinusoidal form 64. The arrangement of the arcuate segments 70 is not limiting. For example, one wave of the sinusoidal form 64 can include three arcuate segments between the peaks and valleys, while another wave of the sinusoidal form 64 can include six arcuate segments between the peaks and valleys. Thus, it should be appreciated that the sinusoidal form 64 can be irregular. The arcuate segments 70 can be formed at locations of the plate 62 that are proximate or otherwise positioned to contact the vehicle component 24, such as the battery assembly 24a.

[0091] The number of arcuate segments 70 can vary along the length "L" of the plate 62. For example, the number of arcuate segments 70 in the load portion 66 of the plate 62 can be greater than the number in the non-load portion 68 of the plate 62. By varying the number of arcuate segments 70, the weight and energy absorption capacity of the plate 62 can be adjusted according to the expected load or impact forces. For example, a higher number "N" of arcuate segments 70 can result in a lower weight and higher energy absorption capacity of the plate 62 compared to a lower number "N" of arcuate segments 70. Thus, the energy absorption device 12 can provide a variable weight and energy absorption capacity along the length "L" of the plate 62, thereby enhancing the performance and efficiency of the energy absorption device 12.

[0092] Referring again to Figure 7 and now referring to Figure 8 , another aspect of the energy absorption device 12 according to the principles described herein is provided. In one aspect, the plate 62 can be formed from a first material plate 72 and a second material plate 74 that are coupled together to form a monolithic structure. In one aspect, the first material plate 72 is formed from the same material as the second material plate 74. In another aspect, the first material plate 72 is formed from a different material than the second material plate 74. The first material plate 72 is joined to the second material plate 74 to form a plurality of tubes 76 that are interconnected to one another by neck portions 78. Figure 7 and Figure 8 depicts one aspect in which the sinusoidal form 64 of the first material plate 72 is mirrored with the sinusoidal form 64 of the second material plate 74, and the thickness of the first material plate 72 and the second material plate 74 are the same and uniform along the length of the plate 62. However, it should be appreciated that the first material plate 72 and the second material plate 74 can have different thicknesses "T", widths, wavelengths, and amplitudes.

[0093] Figure 7 and Figure 8An aspect is shown in which the first material panel 72 has the same number of arcuate segments 70 as the second material panel 74, and the arcuate segments 70 are mirror images of each other. However, it is appreciated that the first material panel 72 can include a different number of arcuate segments 70 than the second material panel 74, and the arcuate segments 70 of the first material panel 72 are not aligned or otherwise mirror images of the second material panel 74 in order to form the tubes 76 having irregular diameters. The tubes 76 can increase the strength and rigidity of the panel 62, as well as the energy absorption capacity of the panel 62. The neck portion 78 can provide a connection between the tubes 76, as well as the flexibility and deformability of the panel 62. It is also appreciated that the first material panel 72 and the second material panel 74 can be formed from a single material panel 62, in which case the reference to the first material panel 72 and the second material panel 74 is simply to refer to portions of the tubes 76 and the neck portion 78.

[0094] Referring now to Figure 10 In another aspect of the disclosure, the carrier 46 includes planar surfaces that extend along the length of the panel 62 and are interposed between the panel 62 and at least one of the inner rocker 28 and the outer rocker 30. In such an aspect, the carrier 46 includes a top wall 80a, a bottom wall 80b, a front wall 80c, and a rear wall 80d that are connected to each other to form a rectangular tube having a through hole that is configured to receive the panel 62. The front wall 80c and the rear wall 80d are planar surfaces and are configured to press against each side of the panel 62. Thus, during an impact, energy is transferred along the wave form through the planar surfaces of the front wall 80c or the rear wall 80d, as the case can be. In such an aspect, the carrier 46 can be formed from a durable and rigid material, such as steel. The length of the carrier 46 can be substantially the same as the length of the panel 62, and the width of the carrier 46 is wider than the width of the panel 62, but is sized so that the sides of the panel 62 are in contact with the interior surfaces of the front wall 80c and the rear wall 80d. The flange 60 can be attached to the carrier 46 using known attachment techniques and / or mechanical fasteners, such as welding, bolts, screws, adhesives, etc. As described above, the flange 60 can be used to attach the carrier 46 within the interior space 44 of the rocker assembly 22.

[0095] Referring now to Figure 11In another aspect of this disclosure, the support member 46 is formed of a first plate 82a and / or a second plate 82b. The first plate 82a and the second plate 82b are planar and configured to press against each side of the plate 62. Therefore, during impact, energy is transferred along a wave pattern through the planar surfaces of the first plate 82a and the second plate 82b, depending on the circumstances. In this respect, the first plate 82a and the second plate 82b can be formed of a durable and rigid material, such as steel. The lengths of the first plate 82a and the second plate 82b can be substantially the same as the length of the plate 62. A flange 60 can be attached to the first plate 82a and the second plate 82b using known attachment techniques and / or mechanical fasteners, such as welding, bolts, screws, adhesives, etc. As described above, the flange 60 can be used to attach the first plate 82a and the second plate 82b within the internal space 44 of the sill assembly 22 so as to position the first plate 82a and the second plate 82b in contact with the sides of the plate 62. For example, flange 60 can be used to fix the first plate 82a between plate 62 and inner sill 28, and the second plate 82b between plate 62 and outer sill 30.

[0096] In operation, the energy absorption device 12 is positioned to withstand lateral impacts, such as impacts along the width of the vehicle 10. Because the width of the plate 62 extends along the width of the vehicle 10, the plate 62 is configured to receive lateral impacts and be crushed, broken, or otherwise crushed under a predetermined load. The energy absorption device 12 can be adjusted to fit the vehicle component 24 by adjusting the thickness of the plate 62 or the number of arcuate sections 70 along the length of the plate 62. Thus, in areas of the vehicle 10 containing vehicle components such as the battery assembly 24a, the energy absorption device 12 can be configured to protect the vehicle 10 components by increasing the thickness of the plate 62 or including the arcuate sections 70. It should be understood that, due to its composite material composition, the energy absorption device 12 can provide better energy absorption characteristics on a weight basis compared to energy absorption structures made of metal. Therefore, the energy absorption device not only provides the benefits of impact damping but also improves vehicle efficiency by reducing weight.

[0097] Many embodiments have been described. However, it will be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Therefore, other embodiments are also within the scope of the following claims.

[0098] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular construction are generally not limited to that particular construction, but where applicable, they are interchangeable and can be used in selected constructions, even if not specifically shown or described. This can also be varied in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. An energy absorption device for use in a vehicle, the energy absorption device comprising: A plate formed of a composite material, the plate having a width extending along the width of the vehicle and a length extending along the length of the vehicle, wherein the plate has a sinusoidal shape formed along the length of the plate.

2. The energy absorption device according to claim 1, wherein, The thickness variation of the material plate.

3. The energy absorption device according to claim 1, wherein, The sine form is irregular.

4. The energy absorption device according to claim 3, wherein, The plate includes a plurality of arcuate segments along the sinusoidal shape, and the number of arcuate segments in the load-bearing portion is greater than the number of arcuate segments in the unloaded portion.

5. The energy absorption device according to claim 1, wherein, The plate is a first material plate and a second material plate, the first material plate being connected to the second material plate to form a plurality of tubes interconnected with each other through a neck portion.

6. The energy absorption device according to claim 1, wherein, The composite material is selected from the group consisting of carbon fiber reinforced polymers, glass fiber reinforced polymers, aramid fiber reinforced polymers, and natural fiber reinforced polymers.

7. A door sill assembly for use in a vehicle, the door sill assembly comprising: An inner and outer sill are joined together to enclose the interior space, the inner and outer sills extending along the length of the vehicle. Supporting components installed within the internal space; and An energy-absorbing device is disposed within the internal space and held by a support member, wherein the energy-absorbing device is a plate formed of a composite material, the plate having a length extending along the length of an inner threshold and a width extending between an inner threshold and an outer threshold, wherein the plate has a sinusoidal shape extending along the length of the plate.

8. The threshold component according to claim 7, wherein, The inner and outer thresholds are made of metal.

9. The threshold component according to claim 7, wherein, The support member includes a first flange configured to attach between the inner sill and the outer sill.

10. The threshold component according to claim 7, wherein, The support includes a fastening member for attaching to one of the inner or outer sills.

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